BOMAG BW 135 AD BW 138 AD BW 138 AC Tandem Vibratory Roller Service Manual – 2007

Description

BOMAG BW 135 AD BW 138 AD BW 138 AC Tandem Vibratory Roller Service Manual – 2007

This BOMAG BW 135 AD BW 138 AD BW 138 AC Tandem Vibratory Roller Service Manual is the complete workshop-level repair and maintenance reference for these three tandem roller variants, covering both the AD (dual drum) and AC (combination drum and rubber wheel) configurations. Spanning 478 pages, it gives mechanics and fleet technicians the full scope of procedures, specifications, test values, diagnostic flowcharts and component-level repair instructions needed to keep these compact tandem rollers working correctly. The manual is organised into thirteen chapters that move from general repair practice through to full supplier documentation and circuit diagrams, so everything from a routine oil change to a travel pump neutral adjustment is covered in one document.

File Details

• Manual type: Service Manual
• Brand: BOMAG
• Models covered: BW 135 AD, BW 138 AD, BW 138 AC
• Document number: 00891444
• Year of publication: 2007
• Language: English
• Page count: 478
• File format: PDF

Chapters Covered

• General – Introduction, safety regulations, general repair instructions and tightening torques
• Maintenance – General notes, fuels and lubricants, running-in instructions, maintenance chart
• Technical data – Dimensions, weights, travel characteristics, engine data, pump and motor data
• Tests and adjustments – Special tools, rotation speeds, pressure tests in travel and vibration circuits, neutral position of the travel pump (Sauer pump), leakage rate of the vibration motor, steering circuit pressure test
• Trouble shooting – General notes and full trouble shooting diagram for travel, vibration, steering and brake systems
• Fundamental electrics – Circuit diagrams, terminal designations, current, voltage, resistance, series and parallel circuits, Ohm’s law, diodes, relays, fuses, batteries, three-phase generator, electric starter, Telemecanique switch, inductive proximity switches, angle sensor, plug connectors
• Special tools, electrics – Measuring equipment and special tools for electrical diagnostics
• Machine related electrics – Vibration module and Module A68 seat contact monitoring
• Flushing and bleeding – Special tools, flushing schematics for front and rear drum drives, wheel drive motors and vibration circuit, bleeding the travel circuit
• Drum – Special tools, repair overview, removing and installing the drum, dismantling and assembling the drum
• Oscillating articulated joint – Special tools, repair overview, removing, installing, dismantling and assembling the oscillating articulated joint
• Suppliers documentation – Travel pump A10VG28 (Bosch Rexroth), travel pump series 42 (Sauer), drum drive MK05/08/11/18 (Poclain), wheel drive MS/MSE 02…18 (Poclain)
• Circuit diagrams – Wiring diagrams and hydraulic diagrams

The document is far more than a routine maintenance schedule. It is a structured service manual that breaks each major assembly down into removal, dismantling, inspection, reassembly and adjustment steps, with tightening torques, nominal values and test pressures stated throughout. The trouble shooting chapter alone uses a flowchart format that leads a technician through each system – travel, vibration, steering and brake – from a symptom to a specific component or adjustment. That means an experienced mechanic can diagnose a fault without guesswork and then follow the repair instructions to correct it.

The hydraulics coverage is especially thorough. The manual includes pressure test procedures for the travel circuit, vibration circuit and steering circuit, along with the exact nominal values a technician should expect to see at operating temperature. There is also a dedicated flushing and bleeding chapter with schematics for the front drum drive, rear drum drive, rear wheel drive motors and the vibration circuit – a critical procedure after any component replacement to prevent contamination from damaging the rebuilt system. The supplier documentation section extends this by reproducing the full repair instructions for the Bosch Rexroth A10VG28 travel pump, the Sauer series 42 travel pump, the Poclain MK05/08/11/18 drum drive motors and the Poclain MS/MSE wheel drive motors, including exploded views, disassembly sequences, reassembly torque values and adjustment procedures. This alone makes the manual valuable for anyone working on the hydrostatic drive components of these rollers.

On the electrical side, the manual starts from fundamental electrics and works up to machine-specific circuits. It explains terminal designations, how to read circuit diagrams, voltage and resistance measurement, diodes, relays, fuses, batteries, three-phase generators, starters, inductive proximity switches and the angle sensor used on these machines. The wiring diagrams for the BW 135 AD, BW 138 AD and BW 138 AC are included, along with hydraulic diagrams, so circuit-level fault finding is fully supported. The machine-related electrics chapter covers the vibration module and the Module A68 seat contact monitoring system, including its pin assignments, inputs, outputs, emergency operation and the French and standard option behaviours.

Because the manual covers three distinct machines, it is worth noting that some sections apply only to specific models or configurations. The BW 135 AD uses a Bosch Rexroth A10VG28 travel pump, while the BW 138 AD and BW 138 AC use a Sauer series 42 travel pump. Vibration frequency, amplitude and engine data are tabulated separately for each model. The BW 138 AC is the combination roller, so it has rubber wheels at the rear instead of a second drum, and the wheel drive motor documentation applies to that configuration. The manual flags these differences where they matter, but a technician should always confirm the model and serial number before ordering parts or applying a specific pressure value.

The opening chapter sets out the safety regulations, general repair instructions and tightening torque tables that apply across the whole machine. It covers metric screws in strength classes 8.8, 10.9 and 12.9, metric fine thread, UNC and UNF threads, wheel nuts, and screws treated with anti-seize paste. This is the reference data a mechanic needs when reassembling any part of the roller, and having it in the same document as the repair procedures removes the need to hunt through separate tables.

For day-to-day maintenance, the manual includes the full maintenance chart with intervals from every 10 operating hours through to every 5000 operating hours, covering engine oil checks, hydraulic oil level, fuel level, water level in the sprinkler system, emulsion level, greasing the articulated joint, cleaning cooling fins and hydraulic oil cooler, adjusting scrapers, servicing the battery, draining sludge from the fuel tank, changing engine oil and filters, checking valve clearance and V-belt tension, and replacing toothed belts. It also specifies the fuels and lubricants to use, including engine oil viscosity by ambient temperature, hydraulic oil HV 46, and biodegradable hydraulic oil options.

Technical data is presented in a dedicated chapter with dimensions in millimetres, operating weights, mean axle loads, static linear loads, oscillation angle, inner track radius, travel speeds, gradability, engine data, travel pump data, drum drive motor data, wheel motor data, vibration pump and motor data, steering valve data, and noise and vibration values. This is the chapter a technician uses to verify a machine is within specification or to look up a pressure or flow rate before testing.

The drum chapter covers removal, installation, dismantling and assembly of the drum, including the exciter shaft, vibration bearings, rubber buffers, coupling and bearing housing. It includes the end float measurement procedure for the exciter shaft, with a nominal value of 0.6 mm to 1.9 mm, and the tightening torque for the rubber buffers. The oscillating articulated joint chapter covers removal, installation, dismantling and assembly of the joint, including the taper roller bearings, tensioning nut adjustment and rocker bearings. These are the two assemblies most likely to need major service on a tandem roller, and having the full procedure with tool references and torque values makes the job far more approachable.

This BOMAG tandem vibratory roller service manual is intended for trained mechanics, workshop technicians and fleet maintenance personnel who need to carry out repairs to the manufacturer’s procedures rather than relying on generic advice. It supports engine servicing, hydraulic system testing and repair, electrical fault finding, drum and exciter shaft overhaul, articulated joint rebuilding, flushing and bleeding after component replacement, and adjustment of travel pump neutral positions. The procedures are written for the technician who already understands basic mechanics and hydraulics but needs the specific values, sequences and safety notes that apply to the BW 135 AD, BW 138 AD and BW 138 AC. Used properly, it helps avoid the two most common causes of repeat failure on these machines – incorrect assembly torque and contaminated hydraulic oil after a repair.

Delivered as an instant PDF download, the manual can be stored on a laptop, tablet or phone and printed page by page for use in the workshop. There is no shipping and no waiting for a physical book to arrive. Whether you are servicing your own roller, maintaining a rental fleet, or working as a mobile mechanic, having the complete service manual on hand means you can check the correct procedure before you start the job, not after something goes wrong.